EP4133176B1

EP4133176B1 - Device and method of controlling blade instabilities of a wind turbine to avoid blade fluttering

Info

Publication number: EP4133176B1
Application number: EP21728042.9A
Authority: EP
Inventors: Johannes Gerhardes Wardjan Alberts; Bjarne Skovmose Kallesoee
Original assignee: Siemens Gamesa Renewable Energy AS
Current assignee: Siemens Gamesa Renewable Energy AS
Priority date: 2020-06-05
Filing date: 2021-05-21
Publication date: 2023-11-08
Anticipated expiration: 2041-05-21
Also published as: EP3919738A1; US11905932B2; WO2021244871A1; CN115667702A; US20230220830A1; EP4133176A1; DK4133176T3

Description

Field of invention

The present invention relates to a device and a method of controlling blade instabilities of a wind turbine to avoid blade fluttering.
Fig. 3 shows a graph of a fluttering speed F [RPM] of a rotor of a wind turbine and of safety overspeed threshold values S₁, S₂ [RPM] according to the prior art. The allowable rotor speed or fluttering speed F, at and above which fluttering occurs (i.e. a tip speed depended aeroelastic instability and/or an oscillation of the blade tip with a certain amplitude and/or frequency along an axis of rotation), can be a graph correlating to parameters such as wind speed, pitch angle, rotor speed, etc. The fluttering speed F was usually sufficiently high and above the safety overspeed threshold value S₁, but recent blade optimizations resulted in a lowered fluttering speed F which falls below the safety system overspeed threshold S₁. As a consequence, the safety system overspeed threshold S₁ had to be lowered from S₁ to S₂ (for all wind speeds, pitch angles, etc.) to avoid conditions where fluttering might occur and the blade structural integrity could thus be at stake. A similar approach (but not mentioning blade flutter) is disclosed in WO 2019/212450 .
However, the lowering of the safety system overspeed threshold from S₁ to S₂ causes unnecessary shutdowns (false positives) in operation regions where fluttering would not occur anyhow, for example in mild fault scenarios. This will have a negative impact on availability, grid compliance and power production.
In an alternative approach, efforts have been made to increase the fluttering speed by changing the structural blade properties, which however resulted in a significantly increased blade masses/weights.

Summary of the Invention

There may be a need for a device and a method of controlling blade instabilities of a wind turbine to avoid blade fluttering, where unnecessary shutdowns or structural modifications of the blades are reduced. This need may be met by the subject matters according to the independent claims. The present invention is further developed as set forth in the dependent claims.
According to a first aspect of the invention, a method of controlling blade instabilities of a wind turbine is provided. The wind turbine comprises a rotor having a plurality of rotor blades, the rotor being mounted to a nacelle to rotate about a rotation axis with a rotor speed, wherein each blade is configured to be pitched by a pitch angle about a pitch axis of the blade. The pitch axis is usually a longitudinal axis of the blade. The method comprises a step of defining at least one preliminary overspeed threshold value; defining a fluttering rotor speed at and above which a predetermined fluttering of at least one of the blades occurs, the fluttering rotor speed is defined as a function of the pitch angle and/or as a function of the wind speed; setting a final overspeed threshold value to be equal to or smaller than a minimum rotor speed of the at least one preliminary overspeed threshold value and the fluttering rotor speed at the actual pitch angle and/or at the actual wind speed; and controlling the rotor speed to not exceed the final overspeed threshold value. The wind speed determining device can be a wind speed detector. However, the wind speed can also indirectly be estimated based on other parameters than the wind speed.
In an embodiment, the final overspeed threshold value is acquired from a lookup table as the function of the at least one preliminary overspeed threshold value, the actual pitch angle and/or the actual wind speed.
In an embodiment, the at least one preliminary overspeed threshold value is dynamically changed based on a predetermined parameter or based on a predetermined event. The predetermined event can be a shutdown event or a high wind speed condition, for example. The at least one preliminary overspeed threshold value, which for example initiates a shutdown, can depend on the pitch angle and/or the wind speed and/or a speed reference (target rotor speed). Then the action, the safety system or control device can take, can either be a shutdown or curtailing the rotor speed. This can apply for both a primary layer of protection (for example implemented by a controller monitor/control device of the wind turbine) and a secondary layer of protection (for example implemented by an external hardware outside the wind turbine).
In an embodiment, the at least one preliminary overspeed threshold value includes: a first preliminary overspeed threshold value which is provided from a hardware outside the wind turbine such as from an external safety system; and/or a second preliminary overspeed threshold value which is provided from an internal control device of the wind turbine. The final overspeed threshold value is set to be equal to or smaller than a minimum rotor speed of at least one of the first preliminary overspeed threshold value and the second preliminary overspeed threshold value, and of the fluttering rotor speed at the actual pitch angle and/or at the actual wind speed. For example, the second preliminary overspeed threshold value, which is provided from the internal control device of the wind turbine, can be used in a primary layer of protection, and the first preliminary overspeed threshold value, which is provided from the hardware outside the wind turbine such as from the external safety system, can be used in a secondary layer of protection.
According to a second aspect of the invention, a control device is provided, which is configured to control blade instabilities of a wind turbine. The wind turbine comprises a rotor having a plurality of rotor blades, the rotor being mounted to a nacelle to rotate about a rotation axis with a rotor speed, wherein each blade is configured to be pitched by a pitch angle about a pitch axis of the blade. The control device is configured to set a final overspeed threshold value to be equal to or smaller than a minimum rotor speed of at least one preliminary overspeed threshold value and a fluttering rotor speed, at and above which a predetermined fluttering of at least one of the blades occurs. The fluttering rotor speed is defined as a function of the pitch angle and/or as a function of the wind speed; and the control device is configured to control the rotor speed to not exceed the final overspeed threshold value.
Also here, the predetermined fluttering condition may cause a tip speed depended aeroelastic instability, and it may occur when there is an oscillation or vibration of the at least one blade with a certain amplitude and/or frequency along the axis of rotation. The predetermined fluttering condition can also be defined by any other condition.
In an embodiment, the control device is configured to access a lookup table where the final overspeed threshold value is defined as a function of the at least one preliminary overspeed threshold value, the actual pitch angle and/or the actual wind speed.
In an embodiment, the at least one preliminary overspeed threshold value dynamically changes based on a predetermined parameter or based on a predetermined event.
In an embodiment, the at least one preliminary overspeed threshold value includes: a first preliminary overspeed threshold value which is provided from a hardware outside the wind turbine such as from an external safety system; and/or a second preliminary overspeed threshold value which is provided from the control device of the wind turbine. The control device is configured to set the final overspeed threshold value to be equal to or smaller than a minimum rotor speed of at least one of the first preliminary overspeed threshold value and the second preliminary overspeed threshold value, and of the fluttering rotor speed at the actual pitch angle and/or at the actual wind speed.
According to a third aspect of the invention, a wind turbine comprises the above-mentioned control device.
According to the present invention, the object discussed above is achieved by adjusting the overspeed threshold (for both or one of the safety system and the controller monitor) based on the pitch angle and/or the wind speed. The above discussed disadvantages of the prior art are overcome. In the prior art, the overspeed threshold has been lowered which resulted in an increased number of shutdowns which impaired the availability, power production and grid compliance (e.g. a grid 'low-voltage ride through' (LVRT) or a 'grid fault ride through' (GFRT), both requiring a standby operation).
Alternative prior art efforts tried to strengthen the blade structure to increase the fluttering speed, which was expensive and increased the mass/weight of the blades and the entire supporting structure, and therefore the loads. E.g. blade bolts were not be able to withstand the fatigue loads and needed to be increased in size, which in turn increased the hub size, the nacelle-hub interface, the bedframe and therefore tower and foundation of the wind turbine.
The present invention overcomes these disadvantages by correlating the fluttering to the pitch angle (or wind speed) so that the overspeed threshold is lowered only in that specific region of operation where a fluttering behavior is hazardous. At the same time, this specific region of operation is also the region where the risk of a shutdown after gust events or LVRTs/GFRTs is nearly non-existent. As a result, the structural integrity and the safety of the turbine are improved under low costs and nearly without any loss of availability and power production. The risk of blade damages in the field is reduced, so that possible costs of blade repairs, warranty cases, etc. are also reduced. Eventually, the entire wind turbine costs can be reduced due to lighter structural components that carry the lighter blade.
It has to be noted that embodiments of the invention have been described with reference to different subject matters. In particular, some embodiments have been described with reference to apparatus type claims whereas other embodiments have been described with reference to method type claims. However, a person skilled in the art will gather from the above and the following description that, unless other notified, in addition to any combination of features belonging to one type of subject matter also any combination between features relating to different subject matters, in particular between features of the apparatus type claims and features of the method type claims is considered as to be disclosed with this application.

Brief Description of the Drawings

The aspects defined above and further aspects of the present invention are apparent from the examples of embodiment to be described hereinafter and are explained with reference to the examples of embodiment. The invention will be described in more detail hereinafter with reference to examples of embodiment but to which the invention is not limited.

Fig. 1: shows a wind turbine and the different elements thereof;
Fig. 2: shows a graph of a target rotor speed as a function of the pitch angle according to an embodiment; and
Fig. 3: shows a graph of a fluttering speed and of safety overspeed threshold values according to the prior art.

Detailed Description

The illustrations in the drawings are schematically. It is noted that in different figures, similar or identical elements are provided with the same reference signs.
Fig. 1 shows a wind turbine 1. The wind turbine 1 comprises a nacelle 3 and a tower 2. The nacelle 3 is mounted at the top of the tower 2. The nacelle 3 is mounted rotatable with regard to the tower 2 by means of a yaw bearing. The axis of rotation of the nacelle 3 with regard to the tower 2 is referred to as the yaw axis.
The wind turbine 1 also comprises a rotor 4 with three rotor blades 6 (of which two rotor blades 6 are depicted in Fig. 1). Each blade 6 is configured to be pitched by a pitch angle about a pitch axis of the blade 6. The pitch axis of the blade 6 is usually the longitudinal axis of the blade 6. The pitching is usually performed by a pitch actuator. The rotor 4 is mounted rotatable with regard to the nacelle 3 by means of a main bearing 7. The rotor 4 is mounted rotatable about a rotation axis 8.
The wind turbine 1 furthermore comprises a generator 5. The generator 5 in turn comprises a rotor 10 connecting the generator 5 with the rotor 4. The rotor 4 is connected directly to the generator 5, thus the wind turbine 1 is referred to as a gearless, direct-driven wind turbine. Such a generator 5 is referred as direct drive generator 5. As an alternative, the rotor 4 may also be connected to the generator 5 via a gear box. This type of wind turbine 1 is referred to as a geared wind turbine. The present invention is suitable for both types of wind turbines 1.
The generator 5 is accommodated within the nacelle 3. The generator 5 is arranged and prepared for converting the rotational energy from the rotor 4 into electrical energy in the shape of an AC power.
Fig. 2 shows a graph of a target rotor speed as a function of the pitch angle according to an embodiment and describes a method of controlling blade instabilities of the wind turbine 1.
The method comprises a step of defining a fluttering rotor speed F at and above which a predetermined fluttering condition of at least one of the blades 6 occurs. The fluttering condition can be indicated by an oscillation of the at least one blade 6 with a certain amplitude and/or frequency, for example along the axis of rotation 8.
As shown in Fig. 2, the fluttering rotor speed F is defined as a function of the pitch angle. In the embodiment of Fig. 2, the graph of the fluttering rotor speed F is composed of two different curves, i.e. the curve at the left-hand side in Fig. 2 is ascending, and the curve at the right-hand side in Fig. 2 is descending. Both curves intersect each other at an apex. The graph in Fig. 2 is just an example; as a matter of course, the graph of the fluttering rotor speed F can have different shapes.
The method further comprises a step of defining a first overspeed threshold value S in the shape of a safety overspeed threshold value S, which is usually a straight horizontal line so that the safety overspeed threshold value S is a fixed value against any pitch angle. However, the safety overspeed threshold value S in Fig. 2 is just an example; as a matter of course, the safety overspeed threshold value S can have any shape. For example, the safety overspeed threshold value S can also be a function of the pitch angle and/or a function of the wind speed.
The method further comprises a step of setting a final overspeed threshold value T to be equal to or smaller than a minimum rotor speed of the at least one preliminary overspeed threshold value S and the fluttering rotor speed F at the actual pitch angle; and a step of controlling the rotor speed to not exceed the final overspeed threshold value T.
In the embodiment of Fig. 2, the graph of the fluttering rotor speed F intersects the safety overspeed threshold value S in an intersection point at a pitch angle ϕ. As a result, the final overspeed threshold value T corresponds to the safety overspeed threshold value S for pitch angles being smaller than ϕ, and the final overspeed threshold value T corresponds to the fluttering rotor speed F for pitch angles being greater than ϕ.
The final overspeed threshold value T can be acquired from a lookup table as the function of the at least one preliminary overspeed threshold value S and the actual pitch angle.
In a modified embodiment, the safety overspeed threshold value S can dynamically be changed based on a predetermined parameter or based on a predetermined event. The predetermined event can be a shutdown event or a high wind speed condition, for example.
In the above-described embodiment, the at least one preliminary overspeed threshold value S includes the first preliminary overspeed threshold value S (also referred as safety overspeed threshold value S) which can be provided from a hardware outside the wind turbine 1 such as from an external safety system. The first preliminary overspeed threshold value S can be used in a so-called secondary layer of protection.
Instead of or in addition to the safety overspeed threshold value S, the at least one preliminary overspeed threshold value can include a second preliminary overspeed threshold value which is provided from an internal control device of the wind turbine 1. The second preliminary overspeed threshold value can be used in a so-called primary layer of protection.
If the at least one preliminary overspeed threshold value only includes the second preliminary overspeed threshold value, which is provided from the internal control device of the wind turbine 1, wherein the final overspeed threshold value T is set to be equal to or smaller than a minimum rotor speed of the second preliminary overspeed threshold value and the fluttering rotor speed F at the actual pitch angle.
Otherwise, if the at least one preliminary overspeed threshold value includes both the first preliminary overspeed threshold value (for example the safety overspeed threshold value S), which is provided from a hardware outside the wind turbine 1 such as from an external safety system, and the second preliminary overspeed threshold value, which is provided from the internal control device of the wind turbine 1, the final overspeed threshold value T is set to be equal to or smaller than a minimum rotor speed of the first preliminary overspeed threshold value S, the second preliminary overspeed threshold value, and the fluttering rotor speed F at the actual pitch angle.
The embodiments above can be modified in that the fluttering rotor speed F (and thus also the final overspeed threshold value T) of the rotor 4 is a function of an actual wind speed determined by a wind speed determining device (not shown), instead of being a function of the pitch angle. The embodiments above can also be modified in that the fluttering rotor speed F (and thus also the final overspeed threshold value T) of the rotor 4 is a function of the pitch angle and a function of the actual wind speed determined by a wind speed determining device, instead of being a function of only the pitch angle. The wind speed determining device can be a wind speed detector. However, the wind speed can also indirectly be estimated based on other parameters than the wind speed.
The method above can be implemented in a control device (not shown) which is configured to control blade instabilities (and a rotor speed) of a wind turbine 1, wherein the control device is configured to set a final overspeed threshold value T to be equal to or smaller than a minimum rotor speed of at least one preliminary overspeed threshold value S and a fluttering rotor speed F, at and above which a predetermined fluttering of at least one of the blades 6 occurs, wherein the fluttering rotor speed F is defined as a function of the pitch angle and/or as a function of the wind speed. The control device is configured to control the rotor speed to not exceed the final overspeed threshold value.
The control device can be configured to access a lookup table where the final overspeed threshold value T is defined as a function of the at least one preliminary overspeed threshold value S, the actual pitch angle and/or the actual wind speed.
The safety overspeed threshold value S can dynamically be changed based on a predetermined parameter or based on a predetermined event, for example a shutdown event or a high wind speed condition.
The at least one preliminary overspeed threshold value can include the first preliminary overspeed threshold value S which can be provided from a hardware outside the wind turbine 1 such as from an external safety system. Alternatively or in addition, the at least one preliminary overspeed threshold value can include a second preliminary overspeed threshold value which is provided from the control device of the wind turbine 1. The control device is configured to set the final overspeed threshold value T to be equal to or smaller than a minimum rotor speed of at least one of the first preliminary overspeed threshold value S and the second preliminary overspeed threshold value, and of the fluttering rotor speed F at the actual pitch angle and/or at the actual wind speed.
It should be noted that the term "comprising" does not exclude other elements or steps and "a" or "an" does not exclude a plurality. Also elements described in association with different embodiments may be combined. It should also be noted that reference signs in the claims should not be construed as limiting the scope of the claims.

Claims

A method of controlling blade instabilities of a wind turbine (1), the wind turbine (1) comprising a rotor (4) having a plurality of rotor blades (6), the rotor (4) being mounted to a nacelle (3) to rotate about a rotation axis (8) with a rotor speed, wherein each blade (6) is configured to be pitched by a pitch angle about a pitch axis of the blade (6), the method comprising the following steps:
defining at least one preliminary overspeed threshold value (S);

defining a fluttering rotor speed (F) at and above which a predetermined fluttering of at least one of the blades (6) occurs, the fluttering rotor speed (F) is defined as a function of the pitch angle and/or as a function of the wind speed;

setting a final overspeed threshold value (T) to be equal to or smaller than a minimum rotor speed of the at least one preliminary overspeed threshold value (S) and the fluttering rotor speed (F) at the actual pitch angle and/or at the actual wind speed; and

controlling the rotor speed to not exceed the final overspeed threshold value (T).
The method according to the preceding claim, wherein
the final overspeed threshold value (T) is acquired from a lookup table as a function of the at least one preliminary overspeed threshold value (S), the actual pitch angle and/or the actual wind speed.
The method according to any one of the preceding claims, wherein
the at least one preliminary overspeed threshold value (S) is dynamically changed based on a predetermined parameter or based on a predetermined event.
The method according to any one of the preceding claims, wherein the at least one preliminary overspeed threshold value (S) includes:
a first preliminary overspeed threshold value (S) which is provided from a hardware outside the wind turbine (1) such as from an external safety system; and/or

a second preliminary overspeed threshold value which is provided from an internal control device of the wind turbine (1); wherein

the final overspeed threshold value (T) is set to be equal to or smaller than a minimum rotor speed of at least one of the first preliminary overspeed threshold value (S) and the second preliminary overspeed threshold value, and of the fluttering rotor speed (F) at the actual pitch angle and/or at the actual wind speed.
A control device configured to control blade instabilities of a wind turbine (1), the wind turbine (1) comprising a rotor (4) having a plurality of rotor blades (6), the rotor (4) being mounted to a nacelle (3) to rotate about a rotation axis (8) with a rotor speed, wherein each blade (6) is configured to be pitched by a pitch angle about a pitch axis of the blade (6), wherein
the control device is configured to set a final overspeed threshold value (T) to be equal to or smaller than a minimum rotor speed of at least one preliminary overspeed threshold value (S) and a fluttering rotor speed (F), at and above which a predetermined fluttering of at least one of the blades (6) occurs, the fluttering rotor speed (F) is defined as a function of the pitch angle and/or as a function of the wind speed; and

the control device is configured to control the rotor speed to not exceed the final overspeed threshold value (T).
The control device according to the preceding claim, wherein
the control device is configured to access a lookup table, where the final overspeed threshold value (T) is defined as a function of the at least one preliminary overspeed threshold value (S), the actual pitch angle and/or the actual wind speed.
The control device according to any one of claims 5 and 6, wherein
the at least one preliminary overspeed threshold value (S) dynamically changes based on a predetermined parameter or based on a predetermined event.
The control device according to any one of claims 5 to 7, wherein the at least one preliminary overspeed threshold value (S) includes:
a first preliminary overspeed threshold value (S) which is provided from a hardware outside the wind turbine (1) such as from an external safety system; and/or

a second preliminary overspeed threshold value which is provided from the control device; wherein

the control device is configured to set the final overspeed threshold value (T) to be equal to or smaller than a minimum rotor speed of at least one of the first preliminary overspeed threshold value (S) and the second preliminary overspeed threshold value, and of the fluttering rotor speed (F) at the actual pitch angle and/or at the actual wind speed.
A wind turbine (1) comprising the control device according to any one of claims 5 to 8.